3d-food product forming apparatus and process

ABSTRACT

The present invention is related to a food forming apparatus to produce patties with a form member which comprises moulds in which the patties are formed, whereas the form member is located adjacent to a pressure member and is at least partially made from a porous material.

The present invention is related to a food forming apparatus to producepatties with a form member which comprises moulds in which the pattiesare formed, whereas the form member is located adjacent to a pressuremember and is at least partially made from a porous material.

Food product forming apparatus are known from the state of the art andare used to shape food products, for example meat, fish, spinach orcheese. This apparatus normally comprises either a form plate which ismoving reciprocally from a fill-position to a discharge-position. In adifferent embodiment, the machine comprises a rotating form drum inwhich the products are formed and subsequently discharged. In manycases, the mould, in which the food products are formed into patties isat least partially made of a porous material. This porous material hasthe advantage, that the mould can be vented during filling and that amedium, for example air, can be discharged through the porous materialin order to remove the formed patties from the mould. In most cases,these patties are shaped disc-like; i.e. 2-D-shaped. However, there isan increasing demand to provide patties with a more complex structure,3D-structure.

It was therefore the objective of the present invention to provide afood product forming apparatus and a process in which more complexpatties can be produced.

The problem is solved with a food forming apparatus to produce pattieswith a form member which comprises a mould in which the patties areformed, whereas the form member is located adjacent to a pressure memberand is at least partially made from a porous material and the pressureelement is 3D-shaped.

The present invention relates to a food product forming apparatus. Thisapparatus comprises a form member in which the food product, for exampleminced meat, is brought into the desired shape. This form member can beeither a form plate or a form drum. In case the form member is a formplate, this plate moves reciprocally from a fill-position to adischarge-position. In case the form member is a drum, this drum rotatescontinuously. In one angular position of the drum, moulds in the drumare filled with the food and in another angular position, the formedpatties are discharged.

According to the present invention the form plate is located adjacent toa pressure member and preferably between a de-aeration member,preferably a plate or a drum and the pressure member. The de-aerationmember allows the venting of the mould, while it is being filled. Thede-aeration member can also be used to connect the mould to a pressuremedium source, for example to eject the patties from the mould. Theperson skilled in the art understands that the venting-function and theconnection to a pressure medium source can also be integrated into theform member. The de-aeration member is normally located on the oppositeside of the form member relative to side, from which it is filled, whilethe pressure member and the means to fill the mould are located on thesame side. The pressure member is preferably used to avoid leakagesduring the filling of the food mass into the mould, to compress the foodproduct at least slightly in the mould and/or to cut off the material inthe mould from the food mass supply in a fill chamber.

In order to form the food product into patties, the form membercomprises at least one, preferably a plurality of moulds, which are atleast partially made of a porous material. The porous material has theadvantage, that the mould can be vented during filling of the mould toremove entrapped air and/or to supply a pressurized medium, for exampleair, to eject the formed patties out of the mould. Preferably, at leastthe bottom of the mould is made of a porous material.

The form member can be made entirely out of a porous material or theform member can comprise one or more porous inserts. These inserts cancomprise one or more moulds. Preferably, the moulds are not exchangeablebut irreversibly coupled with the plate, for example by gluing, welding,soldering and/or a friction-fit. The porous structure can be made out ofsintered material, for example stainless steel, plastic, aluminum,ceramics and/or a combination of these materials. The same is true forthe porous inserts. The mould can consist of a porous side wall and aporous bottom wall or only of a porous bottom wall. The porecross-section of the porous material is preferably designed such that itis permeable for gas, preferably air. Preferably the pore diameter isfrom 2 to 40 microns. When only using a permeable bottom wall, the othersurfaces of the mould are preferably made of an anti-stick material,like Teflon, and/or coated with such a material. Preferably, the mouldallows the forming of a 3D-shaped product; i.e. a product that does notcomprise a constant thickness over its entire extension. Thus, thebottom of the mould is preferably not flat but 3D-shaped.

The porous structure can be made for example by milling, laser drillingor spark erosion or sintering, preferably direct sintering of the porousstructure into a cavity of the plate. In that way, the pores will not beclosed or only closed to a very small degree during its manufacturing.

In order to provide a high capacity, the inventive food product formingapparatus preferably comprises multiple moulds arranged in a row. Evenmore preferably, the inventive apparatus even has multiple rows, eachrow comprising a plurality of moulds. These rows can be in a continuousprocess filled one after the other. In a discontinuous process, when forexample a reciprocating plate is used, two or more rows are preferablefilled simultaneously.

As already mentioned above, the moulds are preferably connected to theambient and/or a pressure medium supply, for example a gas and/or watersupplies. This takes preferably place via the de-aeration member. Themoulds in one row are preferably connected, for example via a channel tothe ambient and/or to the pressure medium supply. The connection can bepart of the form member itself, in the de-aeration member, in amanifold, which is connected to the form member or in the adjacentsurface between the form member and the manifold or the de-aerationmember. When using multiple rows of moulds in a form member, especiallyfor large capacities, all moulds can be connected with each other.However, a separation of the ventilation and/or pressure medium supplyper row is preferred in order to provide a homogenous supply of thepressure medium.

After the patties have been formed they have to be removed from themoulds. This is preferably done by ejecting a gas, preferably air,through the porous structure of the mould. Preferably, the ejection isan impulse. In case air is not sufficient to remove all food productsfrom the mould, preferably water or another fluid is preferably insertedmost preferably sprayed into the mould prior to its filling. In casethat the form member is a plate, this can be done during the ingoingstroke of the plate; i.e. during the movement of the plate from thedischarge to the filling position. With this fluid, a thin film will becreated on the bottom wall and/or on the side walls of the moulds, whichat least partially prevents the food product from sticking against thewall.

The product to be formed is pressed from a fill chamber into the mouldsof the form member. During this filling air entrapped in the form platemould will escape via the porous structure of the mould into theatmosphere.

An option when processing an extremely sticky food product is to blowair with low air pressure in the mould or to avoid, that the mould isvented so that a film of air is at least locally created between thefood product and the mould.

In case the formed patty is a thin product, preferably the airventilation is closed and/or a negative pressure is created between themould and the patty. This hinders the patty to fall out of the mouldduring the movement of the form member.

In case the mould comprises a porous bottom and a porous sidewall,preferably the bottom and the side wall comprise a separate ventilationand/or pressure medium supply, respectively.

According to one embodiment of the present invention the form member isa plate, which reciprocates between a filling and a discharge position.Such a forming plate is for example described in EP 0 818 148 A1. Thispatent application is hereby included by reference so that itsdescription is part of the present description.

In this patent application a forming machine is described with a springelement, for example an o-ring which presses the pressure member, here apressure plate against the form member, here a from plate and the formmember against a de-aeration member. The clearance between the pressuremember, the form member and the de-aeration member is eliminated withthe spring element and no leakage takes place. The pressure member hasaccording to another or a preferred embodiment of the present inventioncutting means such that the form product is cut when the form plate ismoving from the filling to discharge position.

In order to insure a minimum surface pressure and still adequate sealingbetween the pressure member and the form member, the pressure member ispreferably flexible, so that it equalizes roughness and/or unevenness inthe surface of the forming plate.

Even more preferably, the pressure of the pressure element can beadjusted, for example by an inflatable O-ring. This ring can be insertedinto an indentation in the surface of the pressure member. Its shape,preferably its diameter can be altered for example by pressurized airand/or pressurized water. The pressure of the pressure element ispreferably controllable even more preferably controllable by a computersystem. The pressure is preferably adjusted depending on the material ofthe form member and/or the material of the pressure plate, the wear ofthe form member and/or the pressure member and/or based on the foodproduct to be formed. The pressure plate can comprise two or morepressure elements whose pressure can preferably be altered independentlyfrom each other.

In a preferred embodiment, the apparatus comprises a base member, whosesurface preferably interacts with the pressure member. The pressureelement is preferably located between the pressure member and the basemember. More preferably, the surface adjacent to the pressure member is3D-shaped, to assure a 3D-shaped product can be removed from theinventive apparatus, especially an apparatus with a form plate.

To ensure that especially fibrous food products as whole muscle meat,spinach or the like are not withdrawn from the mould during the movementof the form member, for example during the outgoing stroke, a knifepreferably a knife with a serrated and/or waived blade in the pressuremember is provided according to an inventive or preferred embodiment ofthe present invention. In order to assure high hygiene, the knife ispreferable integrated into the pressure member itself; i.e. the pressuremember and the knife are preferably one piece of material. Preferably,the pressure member comprises an opening through which the food productis fed into the moulds. The knife is preferably provided at thecircumference of this opening. The blade of the knife is preferablyproduced by water-jet cutting. When the form member with its mould isfully charged with food product, the form member moves to its dischargeposition and passes the stationary mounted knife and the bottom side ofthe formed product and its fibers will be cut off.

According to another or a preferred embodiment of the present invention,the apparatus comprises an insertion unit to insert a stick into eachpatty. The stick is especially desirable in case, the food product is socalled finger-food. More preferably, the means is a slot.

Preferably, the insertion unit is located at the front end of the formmember, which is even more preferably a drum.

In a preferred embodiment of the present invention, the insertion unitis movable, preferably along at least a segment of a circular arc. Thus,the insertion unit can, for example, co-rotate together with a drum, sothat the drum can be operated continuously.

In another preferred embodiment of the present invention, the foodproduct forming apparatus comprises a cam that pushes the stick into thepatty, while the form member, especially the drum, is advancing. Thestick is only inserted into the cavity and/or the formed patty and thenpushed into the patty by the cam. The cam can be shaped as a ramp.Preferably, the cam is located at the front end of a drum.

Preferably, the stick is inserted into the food product during themovement of the form member from the filling to the discharge position.Another subject matter of the present invention is therefore a processfor the insertion of a stick into a patty, which are formed in a formingmember, whereas the stick is inserted while the forming member advances.

Another subject matter of the present invention is a process for theinsertion of a stick into a patty, which is formed in a forming member,whereas the stick is at least partially inserted while the formingmember advances and/or whereas the stick is moved relative to theforming member for insertion into the patty by an insertion unit.

In a preferred embodiment of the inventive process, the forming memberis a drum. Preferably, the rotation is stopped or maintained during theinsertion of the stick.

Preferably, the insertion of the stick in one row and filling of thecavity in another row takes place at least partially simultaneously.

Another preferred or inventive embodiment of the present invention is afood forming apparatus with a mould-plate that is reciprocable betweentwo positions and that comprises cavities, which are filled in thefilling station with a patty-material and which are emptied in thedischarge station and which comprises a stationary plate, whereas itfurther comprises rolling elements located between the plate and themould-plate.

The present invention relates to a food forming apparatus. In the foodforming apparatus, a patty material for example any formable, eatablematerial such as a dough, minced meat or the like, can be formed into adesired shape. This shape can be two dimensional, i.e. a disc or threedimensional, i.e. a ball. According to the present invention, the foodforming apparatus comprises a mould plate that reciprocates between twodifferent positions; i.e. a filling and a discharge position. This mouldplate comprises cavities, into which the patty material is filled,preferably pressed and thereby formed. The mould plate preferablycomprises a multitude of cavities which are arranged in an array, i.e.which comprise a multitude of parallel rows, each row preferablycomprising a multitude of cavities. The rows are preferably arrangedperpendicular to the direction of motion of the mould plate. Preferably,the cavities in one row and/or one or more rows are filledsimultaneously in the filling station. Preferably, the cavities in onerow and/or one or more rows are then emptied simultaneously in thedischarge station.

According to the present invention, the inventive food forming apparatuscomprises a plate, which is preferably part of the housing of the foodforming apparatus and thus stationary. Between this plate and at leastone surface of the mould plate, rolling elements are arranged. Theserolling elements reduce the friction of the mould plate during itsmotion between the two positions. Additionally the rolling elementsprovide a large contact area against which the mould plate can bepressed directly or indirectly. Due to the large contact area, no oronly little pressure-peak occur and/or the mould plate does not bend.

Preferably, the rolling elements are provided in a cage, in order toprevent that the rolling elements touch each other and/or have alwaysequal distance from each other

In a preferred embodiment of the present invention, the length of therolling elements is essentially equivalent to the width of the mouldplate, i.e. the horizontal extension of the plate perpendicular to itsdirection of motion. The rolling elements are preferably cylinders morepreferably with a relatively small diameter, for example 10-30 mm,preferably 15-25 mm and even more preferably 19-21 mm. Preferably thesecylinders are arranged side by side with a relatively small distance inbetween, i.e. only sufficient space that the cylinders do not touch eachother. This preferred embodiment of the present invention assures, thatthere are no or little pressure peaks; i.e. that there is an equalpressure distribution along the mould plate, especially along the partof the mould plate where the mould cavities are located.

In another preferred embodiment of the present invention, the foodforming apparatus comprises a locking plate adjacent to the mould plateand fixed to the mould plate. Preferably the rolling elements arearranged between the stationary plate of the food forming apparatus andthe locking plate. The locking plate prevents that the material will bepressed out of the form plate and/or is utilized as a counter plate forthe rollers to avoid indentations from the rollers into the form plate.

Preferably the food forming apparatus comprises a bottom plate.

In another preferred embodiment of the present invention, the foodforming apparatus comprises a seal plate between the bottom plate andthe mould plate. This seal plate seals especially the area around theinlet of the food forming material. Furthermore, the seal plate assures,that the food forming material is only distributed in the cavity but notaround the cavity. Material, that stands out of the cavity is preferablycut off by the seal plate. Thus, in a preferred embodiment, the sealplate comprises cutting means to cut off food forming material thatstands beyond the mould cavity.

Preferably, the seal plate is pressed against the mould plate withspring elements preferably adjustable spring elements. With theadjustment of the spring elements, the pressure between the seal plateand the bottom plate can be adjusted based on the food forming material.Furthermore, wear can be equalized.

Preferably, the mould plate comprises a porous mould region. In thisporous mould region, the mould plate is made of a porous material, forexample a sintered material. Through this porous material air can beejected to remove the formed patties out of the cavities. Furthermore,the passages in the porous material can be utilized to vent thecavities.

Preferably, the porous mould region is an insert into a frame of themould plate. Preferably, the insert comprises a multitude of cavities.The cavities are for example inserted into the porous mould region bymetal cutting.

In another preferred embodiment, the mould region comprises one insertper cavity.

In a yet another preferred embodiment of the present invention, the foodforming apparatus comprises one or more means to divide the airflowbetween two or more cavities or rows of cavities. This embodiment of thepresent invention is especially advantageous to avoid air-shortcuts.Preferably this means is not only present in the gap between the airinlet and the mould- and/or the locking plate but extends also at leastpartially into the porous material. Additionally or alternatively, themeans can be utilized to secure an insert in the plate and/or as apressure member, to assure that the insert is tight relative to the formplate.

Another inventive or preferred embodiment of the present invention is afood forming apparatus with a mould-plate that is reciprocable betweentwo positions and that comprises cavities which are filled in thefilling station with a patty-material and which are emptied in theremoval station, whereas it comprises two discharge stations and onebelt per removal station.

The present invention relates to a food forming apparatus. In this foodforming apparatus, a patty material which is formable, for example adough, minced meat or the like, can be formed into a desired shape. Thisshape can be two dimensional, i.e. a disc or three dimensional, i.e. aball. According to the present invention, the food forming apparatuscomprises a mould plate that reciprocates between two differentpositions; i.e. a filling and a discharge position. This mould platecomprises cavities, into which the patty material is filled, preferablypressed and thereby formed. The mould plate preferably comprises amultitude of cavities which are arranged in an array, i.e. whichcomprise a multitude of parallel rows, each row preferably comprising amultitude of cavities. The rows are preferably arranged perpendicular tothe direction of motion of the mould plate. Preferably, the cavities inone row and/or one or more rows are filled simultaneously in the fillingstation. Preferably, the cavities in one row and/or one or more rows arethen emptied simultaneously in the discharge station.

According to the present invention, the inventive food forming apparatuscomprises two discharge stations, which are located to the left and theright of the filling station. The mold plate reciprocates between thesetwo stations. In these discharge stations, the formed patties areremoved from the cavity. According to the present invention, theinventive food forming apparatus comprises an individual belt perremoval station. Thus, the inventive apparatus can be operated with muchmore flexibility than the apparatus according to the state of the art.The two belts can be operated with the same or different speeds. Thetransportation direction of the two belts is preferably identical.Preferably, one belt is longer than the other and more preferably, thelonger belt is operated at a higher speed than the shorter belt.Preferably, the belts are located at least partially at differentheights. More preferably, at least one belt can comprise means to loweror lift it at least partially. In another preferred embodiment of thepresent invention at least one belt comprises different segments, whichmore preferably can be moved even more preferably rotated relative toeach other.

Preferably, at least one belt comprises means to alter the height of thebelt at least partially before and/or during the transportation of thepatties. In a preferred embodiment, the belt is tilted and/or partialsegments of a belt are lowered and lifted. This preferred embodiment ofthe present invention has the advantage, that during the removal of thepatties from the mold plate, the distance between the mold plate and thebelt can be very small, so that deformation or destruction of thepatties during their drop from the mould plate onto the belt can beavoided. During transportation along the belt however, the distancebetween the surface of the belt and the other parts of the inventivefood forming apparatus can be relatively large to avoid a collisionbetween the formed patties on the belt and other parts of the inventivefood forming apparatus.

Preferably, the two belts are connected by a seesaw. One end of thisseesaw can be brought into alignment with each of the belts. Thus, thepatty load of the two belts can be combined on one belt, which islocated downstream of the seesaw. The seesaw preferably also comprises abelt. This belt can be operated at different velocities than thevelocities of the first and/or second belt of the food forming apparatusin order to increase or decrease the distance between two patty rows.This holds also true for the transportation means downstream of theseesaw.

Preferably, at least one of the belts, the seesaw and/or the beltdownstream are shiftable sidewards, i.e. in a horizontal directionperpendicular to the direction of transportation. This preferredembodiment allows to stagger the patties on the belt.

According to a preferable or another inventive embodiment of the presentinvention, the mold plate is at least partially porous. Preferably, thecavities especially their bottom and their sidewall are made of aporous-, for example a sintered-material. This embodiment of the presentinvention has the advantage, that the patties can be ejected out of theplate for example with air. Additionally, the cavity can be vented viathe porous material during filling of the cavities.

In another preferred or inventive embodiment of the present invention,the outlet of the filling station is below the mold plate. Thisembodiment of the present invention has the advantage, that the fillingand the discharge of the mould-plate takes place on the same sides ofthe mold plate, so that there need not be any through-holes in the moldplate.

Preferably, the inventive food forming apparatus comprises two outletmeans, preferably two air outlet means to eject the patties out of themolds. This embodiment of the present invention has the advantage, thatno pistons are needed to remove the patties from the mold plate.

According to another inventive or preferred embodiment of the presentinvention, the mold plate comprises a slot to accommodate a stick. Thesticks are inserted into the patty and are utilized to hold the patty.The slot guides the stick during its insertion into the patty. The stickis preferably inserted into the patty by moving the mold plate relativeto the stick and/or the stick relative to the mold plate. The slot haspreferably a U-shaped, square or rectangular cross-section. Preferably,the slot is in connection with a cavity. This facilitates the insertionof the stick into the patty via the slot. Preferably, the slot extendsfrom the cavity in the mold plate to the side-limit of the mold platethat is oriented perpendicular to the direction of motion.

Preferably, the mold plate comprises to rows of cavities, each rowcomprising at least one, preferably a multitude of cavities, whereas thecavity/cavities in one row are staggered to the cavity/cavities in theother row. This preferred embodiment of the present invention has theadvantage that the patties can be placed on a belt in a staggeredpattern without moving the belt sidewardly.

Another subject matter of the present invention is a process for thetransportation of patties, whereas the patties are staggered. Thisembodiment of the present invention allows to increase the load on thebelt per unit-length. Furthermore it has advantages regarding thesubsequent processing and/or packaging of the patties.

Preferably, the patties comprise a stick, whereas the sticks point atleast partially in different directions. Preferably, one stick points inthe direction of motion of the transportation belt, while the next onepoints in the opposite direction.

The inventions are now explained according to FIGS. 1-32. Theseexplanations do not limit the scope of protection. The explanationsapply to all inventive embodiments of the present invention likewise.

FIGS. 1-4 show one embodiment of the inventive apparatus.

FIGS. 5 and 6 show the inventive pressure member.

FIG. 7 shows another embodiment of the inventive apparatus.

FIG. 8 shows further details of the apparatus according to FIGS. 1-4.

FIG. 9 show the stick insertion.

FIGS. 10-12 show another embodiment of the apparatus with stickinsertion.

FIG. 13 shows a movable insertion unit.

FIG. 14 shows a first embodiment of the food forming apparatus.

FIG. 15 shows a second embodiment of the food forming apparatus.

FIG. 16 shows a first embodiment of the mould plate.

FIG. 17 shows a second embodiment of the mould plate.

FIGS. 18 a-18 e show the operation of the inventive food formingapparatus.

FIG. 19-23 show the inventive food forming apparatus and its operation.

FIG. 24-29 show another embodiment of the inventive food formingapparatus.

FIG. 30 shows the forming of patties with a stick.

FIG. 31 shows a belt loaded with staggered patties.

FIG. 32 shows a mold plate with staggered cavities.

FIGS. 1-4 show one embodiment of the inventive forming apparatus. As canbe seen from FIGS. 1 and 2, the forming apparatus 3 has a housing, whichis denoted overall by 4 and comprises a base member 5, here a plate, ade-aeration member 2, here a plate, lateral guides 6 between these twocomponents (see FIG. 2) and a closure member 7 which holds the parts 2,5 and 6 pressed against one another. The de-aeration member 2 hasventilation holes 8. The holes 8 can be utilized to allow theventilation of the mould 11 during its filling to remove entrapped air.The holes 8 can also be used to eject a gas, for example air into themould to create an air cushion to reduce sticking of the patty in themould. The lateral guides 6, the base member 5 and the de-aerationmember 15 delimit a chamber 9, in which the form member 1 can bedisplaced between a position moved inwards, which is shown in continuouslines, and a position moved outwards, shown by broken lines. The inwardposition of the form member is the so called filling position in which amould is filled with food mass. The outward position is the so calleddischarge position, in which the formed patty is discharged from theform member 11. The base member 5 has a feed opening 10 which isconnected to the feed of the food mass (not depicted). In the moved-inposition of the form member 1, the moulds 11 arranged therein are incommunication with the feed opening 10. According to the invention, thebase member is preferably provided with a recess 12, in which a pressuremember 13, here a plate is situated. The stationary pressure member 13is shown in more details in FIGS. 5 and 6 and has an opening 14 which isaligned with the feed opening 10 in the base member 5. A groove 15 isarranged around this feed opening 14, in which groove a likewiseencircling spring element 16, for example a rubber ring or an O-ring, issituated. This spring element is supported on the base member 5, on itsregion around the feed opening 10. The pressure force resulting from thespring element 16 is preferably adjustable, so that on one hand the feedopening is sealed but on the other hand the sealing force is not toohigh, to avoid wear of the spring element 16, the form member 1 and/orthe pressure member 13 and/or to improve the sealing. The adjustment ofthe pressure force can be, for example, achieved with a hollow O-ring,into which a pressure fluid is filled. The pressure fluid changes thediameter of the O-ring and thus the pressure force. Preferably, thespring element is computer-controlled. As a result, the pressure member13 is held firmly pressed against the form member 1, so that any play ofthe said form member 1 in the internal chamber 9 in the housing 4 iseliminated, in the region of the feed opening 10. The spring element 16also seals the gap between the pressure member 13 and the recess 12. Bydint of this resilient pressure, scarcely any leakage now takes placebetween the pressure member 13 and the form member 1. Moreover, thispressure member 13, interacting with the form member 1, also has acutting action, such that the fibers of the mass, such as meat fibers,are reliably severed when the form member 1 is displaced to itsoutwardly projecting position. In order further to improve the seal ofthe pressure member 13 with respect to the form member 1, preferably afurther groove 17 is provided, in which an additional spring element 18is situated. The pressure force of this spring element 18 is preferablyalso adjustable as described above.

FIGS. 3 and 4 show details of the inventive forming apparatus 10according to FIGS. 1 and 2. This forming apparatus 10 comprises aforming member 1, here a plate, which reciprocates between afilling-position in which the moulds 11 in the plate 1 are filled withthe food product and a discharge position in which the formed foodproducts 22, the patties, are removed from the form member 1. Themovement of form member 1 is depicted by the double arrow on the plate.FIGS. 3 and 4 depict the discharge position of form member 1. Theinventive apparatus 10 preferably comprises a knock out cup 19 which isconnected to a piston 24. The knock out cup 4 moves from astart-position to a knock-out-position and back as shown by the doublearrow on piston 24. The knock out cup 19 comprises at its bottom aperforated plate 20 which is permeable for a fluid medium, preferablygas and/or water. FIG. 3 shows the knock out cup in its start position.FIG. 4 shows the knock out cup after it has come into contact with thefood product 22 in form member 1 and after it has moved through the formmember 1 and has knocked out the food product 22 out of form member 1.After the food products 22 have been removed from form member 1, theyfall on a transportation belt 21 and are transported to the nextprocessing step. The person skilled in the art understands, that formmember 1 can comprise a multitude of moulds and correspondingly amultitude of knock out cups. The knock out cup can be drivenindividually or together in groups. The person skilled in the artfurthermore understands that form member 1 can be substituted by aintermittently or continuously rotating drum with holes in it. In thiscase, the knock out cups are located preferably at the inside of thedrum. The person skilled in the art further understands that thedepiction of the patties 22 is simplified and that they can have a3D-shape. In the case, the bottom of the knock out cup, here the plate20, needs to have a corresponding shape.

FIGS. 5 and 6 show details of the pressure member 13, which is here apressure plate. This plate 13 is stationary and the top surface depictedin FIG. 5 is adjacent to the form member. The movement of the formmember is depicted by a double arrow. As described previously, thepressure member 13 comprises an opening 14 through which the food massis fed into the moulds. This opening comprises a circumference intowhich at least partially, the blade 23 has been worked. The blade 23cuts the food product, for example fibers of the food product forexample muscle-fibers, during the movement of the form member,especially during the outgoing movement of the form plate into thedischarge-position. The blade 23 is located in the pressure member 13such, that the inner surface of the formed patty and/or inner surface ofmould moves entirely across the blade during the movement of the formmember. A person skilled in the art understands that for forming a3D-product it can be necessary to shape the pressure plate 3dimensionally too. In this case, the blade is also 3D-shaped. The plateis preferably worked directly into the material of the pressure-member,i.e. the blade and the pressure member are made out of one piece.Preferably, the blade is serrated and/or waved. Preferably, the blade isproduced by water-jet-cutting.

FIG. 6 shows the backside of the pressure plate according to FIG. 5. Onthis side, grooves 15 and 17 have been worked into the plate which holdspring elements 16, 18 respectively. These spring elements are in thepresent case O-rings, which are preferably adjustable in their diameteras described above.

FIG. 7 shows another embodiment of the inventive forming apparatus. Thedisclosure made regarding FIGS. 1-6 also applies to this embodiment. Inthis case, the form member 1 is a drum that rotates continuously orintermittently. The circumference of the drum comprises several moulds11, which are located at different angular positions and which arepreferably also located in parallel, in rows along the axial extensionof the drum. The moulds 11 comprise in the present case porous insertswhich are embedded in the drum. Each mould 11 is connected to a channelsystem 25, 28 through which the individual mould can be vented and/orthrough which a pressurized medium can be ejected in order to remove theformed patties 22 from the moulds 11.

The inventive forming apparatus further comprises a filling shoe whichsurrounds the circumference of the drum partially. It can be seenespecially from FIG. 7 a, that this shoe comprises adjacent to thecircumference of the drum a pressure plate 13, which is in the presentcase 3D-formed in order to produce 3D-shaped patties 22 which can beespecially seen in FIG. 7 c. Between a base member 5 and the pressureplate 13, pressure transfer means 31, here lamellas, can be located,which transduce a pressure from the base member 5 to the pressure member13. The pressure member 13 is made in the present case of a flexiblematerial so that is always in contact with the surface of the drum. Thebase member 5 comprises pressure means for example spring elements topress the pressure plates against the drum. These spring elements arepreferably as already discussed above adjustable more preferred by acomputer system. The drum rotates, preferably continuously, from afilling position in which the food material is fed into the moulds, to adischarge position, which is depicted in figure c. In this dischargeposition, the formed patties 22 are discharged on a transportation belt21 and transported away.

FIG. 8 shows further details of the embodiment of the inventive formingapparatus according to FIGS. 1-4. In FIG. 8 a, a form plate 1 isdepicted in its filling position. In this filling position, a food mass33 is fed into the individual moulds of the mould plate, which arelocated in parallel in a row. Below the forming plate is a pressureplate 13, which is in the present case 3D-formed; i.e. comprisesindentations in order to allow the production of 3D-shaped productswhich are in the present case sticks with a regular poly-angulardiameter. In order to allow ventilation of the mould during its filling,the mould, which comprises in the present case a porous insert, as canbe seen in FIG. 8 b, is connected to a channel system 25, 28 which canbe connected for example to the ambient and allows the removal of theentrapped air. As depicted by the double arrow on the form plate 1, theform plate is movable from the depicted filling position into adischarge position, which can be seen in FIG. 8 c. FIG. 8 b showsdetails of moulds 11, which are as already said, made from porousmaterial. In the present case, the moulds are inserts, which areinserted into a cavity 26. Each of these cavities 26 is connected to achannel 25 via a branch 28. The branch 28 and/or the channel 25 islocated in a de-aeration plate 2. FIG. 8 c shows the form plate in itsdischarge position. Here, the moulds are connected via channels 25 to apressure medium for example pressurized air which ejects the formed foodpatties 22 out of the moulds 11. The channel 25 is here part of astationary ejector 32. It can be especially seen from FIG. 8 c, that thesurface of the form plate 1, which is adjacent to the pressure plate 13is also 3D-formed, whereas the indentations of the pressure plate fitinto convexities of the form member and vice versa.

FIG. 9 shows the insertion of a stick 29 into the formed food patties22. The insertion of the stick can take place during the movement of theform member 1 from the filling- to the discharge position or after theform member has reached the discharge position. The person skilled inthe art understands that the sticks can be stationary and/or can bemoved to utilized the insertion of the sticks 29. The sticks 29 areinserted into the patties via a slot 30. By means of this slot thepatties and the sticks can be ejected in the discharge position.

FIGS. 10-12 show another embodiment of the inventive apparatus 3, whichcomprises in the present case a drum 1, which rotates, as indicated bythe arrow, counterclockwise. The drum comprises cavities 26, in whichpatties can be formed. Furthermore, the inventive apparatus comprises atboth of its front ends stick insertion units 34, respectively, whereaseach inserts sticks into the patties 22. The patties 22 with its sticks29 inserted are subsequently discharged on a transportation belt 21 andtransported away from the inventive apparatus. As can be especially seenfrom FIG. 11, each cavity 26 is connected to an opening, here a slot 30,through which the stick 29 is inserted into the patty, which is formedin the cavity 26. In the present case, the cavity 26 is made from aporous material.

FIG. 12 shows details of the stick insertion unit 34, which comprises inthe present case an insertion pin 35, which pushes stick 29 into thecavity 26 and thus into the formed patty. The stick insertion unit 34can be either provided stationary or moveable. In case that the stickinsertion unit 34 is stationary, the rotation of the drum must bestopped while the stick is inserted into the patty. In case that theinsertion unit 34 is moveable, it preferably moves along a segment of acircular arch, while it inserts the stick into the cavity. As soon asthis is finalized, the insertion unit 34 moves back into its homeposition and then pushes another stick into the patty. In a preferredembodiment, the inventive apparatus comprises a multitude of rows ofcavities along its circumference. Preferably, while in one row the stickis inserted, another row is filled with the food forming material, atleast partially simultaneously. This can be either done while the formmember is moving or while it is stationary.

In FIG. 13, a moveable insertion unit 34 is depicted. In FIG. 13 a theinsertion unit is shown in its home position. The form member 1, in thepresent case a drum, comprises a multitude of rows with at least onecavity. The drum rotates counter clockwise. As soon as row 1 has reachedthe insertion unit 34, they co-rotate. During this co-rotation (pleasecompare FIGS. 13 b and 13 c) the stick is inserted into the cavity andthus into the patty. As soon as this is finalized (please compare FIG.13 c), the insertion unit rotates clockwise (please compare FIG. 13 d)into its home position and then starts co-rotating with row 2 in orderto insert a stick into the cavity of this row. Preferably, the rotationinto the home position is faster than the co-rotation during theinsertion of the stick.

FIG. 14 shows a first embodiment of an inventive food forming apparatus.This food forming apparatus comprises a top plate 12 and a bottom plate11, which are stationary parts of the inventive apparatus, i.e. itsframe. These plates 11, 12 confine a gap in which a mould plate 17 islocated. The mould plate reciprocates between a filling position 3 and adischarge position 4. The mould plate comprises a frame 2 which ispreferably made from a solid material. Furthermore, the mould platecomprises a porous mould region 7, which is made from a porous materialfor example from a sintered material. In this porous mould region 7,cavities 5 have been machine-cut. The porous mould region 7 preferablycomprises an array of cavities 5, i.e. the cavities arranged in severalrows whereas each row comprises a multitude of cavities. Each rowextends preferably perpendicular to the direction of motion. Thecavities of the each rows are preferably emptied and filledsimultaneously. The cavities of two or more rows can also be emptied andfilled simultaneously. Adjacent to the top surface of a mould plate theinventive food forming machine comprises a locking plate 9. The lockingplate protects the mould plate from above, for example againstindentations from the rollers. Between the locking plate 9 and the topplate 12 a multitude of rolling elements 10 are arranged. These rollingelements extend preferably over the entire width W (please compare FIG.16) of the mould plate 17. In the present case, the rolling elements 10are cylinders with a small diameter, app. 20 mm. These cylinders arearranged side by side with a very small distance in between. In thepresent case, the pitch is 25 mm, so that the distance between therollers is 5 mm. This preferred embodiment of the present inventionassures an equal pressure distribution in the mould plate and no orlittle bending of the mould plate. The rolling elements 10 assure, thatthere is little friction between the mould plate and the frame of thefood forming apparatus, i.e. the stationary top plate 12 during itsmotion between the two positions. Furthermore, the inventive pattymachine comprises an inlet, through which the patty material is insertedpreferably pumped into the cavities 5. This inlet is located in afilling station 6 which itself is located in the filling position 3.

Furthermore, the inventive food forming machine comprises a dischargeposition 4, in which the formed patties are discharged from the mouldplate for example onto a belt 27. In the present case pressurized air,which is forced through the porous material, is used to eject the formedpatties. The food forming apparatus therefore comprises in its dischargeposition 4 a discharge station, in the present case, means to force airthrough the porous region, especially through the cavities morespecifically through the bottom and through the sidewalls of the cavity.

FIG. 15 shows a second embodiment of an inventive food forming machine.In comparison to the food forming machine according to FIG. 14, thepresent food forming machine additionally comprises a seal plate 15,which is located between the bottom plate 11 and the bottom surface ofthe mould plate 17. The seal plate 15 is pressed against the mould plateby spring elements 16, preferably adjustable spring elements 16. Thispressure force also presses the mould plate against the locking plate 9and the locking plate against the rolling elements 10. The seal plateseals the area around the inlet and assures that essentially all thefood forming material is inserted into the cavities and not around thecavities. Furthermore, the seal plate cuts off material that standsbeyond the cavities of the mould plate.

FIG. 16 shows a first embodiment of the mould plate 17. In the presentcase, the porous mould region is made from one piece, which is insertedfor example pressed, screwed, welded, soldered or glued into the frame2. The insert 7 comprises at its lower surface a multitude of cavities,arranged in an array of a multitude of rows, each row comprising amultitude of cavities 5. In order to assure, that there is noair-shortcut regarding the air which is pressed into the porous insertto eject the patties, the inventive food forming machine comprisesdiverters 18 (in the present case four diverters), which are located inthe gap between the locking plate 9 and the mould plate 2 and which alsoextend into the surface of the porous-insert 7.

FIG. 17 shows another embodiment of the mould plate. In the presentcase, the porous elements are discrete elements, which are inserted intoholes in the mould plate. One cavity comprises one individual porouselement. Other than that, it is referred to the explanations accordingto FIG. 16.

FIG. 18 shows the operation of the inventive food forming apparatus. InFIG. 18 a, the cavities 5 are in the discharge position. In thisdischarge position 4, air is forced via an inlet into the cavities 5,especially into the porous mould region 7. The air flows through theporous mould region into the cavities and ejects the patties as depictedby arrow 20. The formed patties preferably fall on a belt and aretransported their way. As soon as the patties have been discharged fromthe mould plate, the mould plate moves to the left as depicted by arrow23 in FIGS. 18 b. During the ingoing stroke and after the mould platehas reached its filling position 3 (FIG. 18 c), food forming material isinserted into the cavities 5, preferably pressed into the cavities ofthe mould plate 17, which is depicted by arrow 21. The porous materialcan be used during this step to remove entrapped air from the cavities.

As depicted in FIG. 18 d, the mould plate is moved back to its dischargeposition 4, as soon as the filling of the cavities is completed, andthen again air is forced through ejection medium supply 8, to remove theformed patties out of the mould plate as can be seen in FIG. 18 e.

FIG. 19 shows the inventive food forming apparatus, which comprises amold plate 2 with a multitude of cavities. In the present example, themold plate comprises four rows of cavities, whereas each row comprises amultitude of cavities 5. The rows are oriented perpendicular to themotion of the mold plate 2. The motion of the mold plate is depicted bythe double arrow. Furthermore, the inventive food forming apparatuscomprises one filling station 6 in which the patty material is pressedinto one or more rows of cavities simultaneously. In the presentexample, two rows of cavities are filled simultaneously. Furthermore,the inventive food forming apparatus comprises a first discharge station7 and a second discharge station 8. In the embodiment according to FIG.19 two rows of cavities 5.1 are presently emptied in the dischargestation 8, while simultaneously two rows of cavities 5.2 are filled withthe food forming material in the filling station 6. As can be seen fromFIG. 19, each discharge station 7, 8 comprises its own belt 9, 10,whereas the first discharge station 8 is adjacent to belt 9 and thesecond discharge station 7 is adjacent to belt 10. In FIG. 19 the formedpatties are presently loaded on belt 9 and transported in a directiondepicted by the arrow. Belt 9 preferably comprises three segments 9′-9′″whereas segments 9′ and 9″ are movable relative to segment 9′,preferably the belt comprises two axis 18, 19, whereas segment 9″ canturn around axis 18 relative to segment 9″′ and segment 9′ can turnrelative to segment 9″ around axis 19. Furthermore, belt 9 comprisesmeans 11, for example motor means, which can lower and lift belt 9especially its segments 9′, 9″.

FIG. 20 shows the situation after the patties (not depicted) have beendropped on segment 9′ of belt 9. Afterwards, this belt is lowered toavoid a collision of the patties especially with the means of thefilling station 6. The patties are transported from the left to theright as depicted by the arrow. Simultaneously or sequentially, moldplate 2 is moved into its second position (please compare FIG. 20) inwhich the cavities which have just been emptied are now filled withpatty material in the filling station. The cavities which have beenfilled in the previous step have now been aligned with the seconddischarge station 7. In this discharge station air is ejected in orderto eject the formed patties (not depicted) on belt 10. Subsequently, ascan be seen in FIG. 22 belt 10 is tilted and thereby lowered in order toavoid a collision between the patties on the belt and the food formingapparatus. Afterwards as can be seen from FIG. 23 the mold plate 9 ismoved back into the position as already depicted in FIG. 19 and theprocess restarts.

As can be seen from FIGS. 19-23, the outlet 13 of the filling station,which is in the present case designed as a plate, has a width so thatfour rows of cavities can be filled simultaneously. Additionally, theoutlet comprises a divider 17, for example a valve, that assures, thatthe patty material is only ejected through the segment of outlet plate13 that is covered by the mold-plate.

FIGS. 24-29 show a second embodiment of the present invention, which isessentially identical to the embodiment according to FIGS. 19-23 so thatthe disclosure regarding FIGS. 19-23 also applies to this embodiment. Inthis embodiment, the first belt 9 is made from one segment and is tiltedin order to increase the space between the belt 9 and the fillingstation especially the distance between segment 9′ and filling thefilling station. Additionally, this embodiment of the present inventioncomprises a seesaw 12, which can be aligned either with belt 9 or withbelt 10. In FIG. 24 the patties are loaded on belt 9. Thus, the seesaw12 is aligned with this belt 9. Then, as can be seen in FIG. 26, themold plate 2 is moved into its second position in which the moldcavities are emptied on belt 10. During this movement or afterwards, theseesaw 12 is tilted so that it is aligned with belt 10, as can be seenin FIG. 27. Then, as depicted in FIGS. 28 and 29, the mold plate 2 ismoved back into its initial position (please compare FIG. 24) and theseesaw is again aligned with belt 10. Due to the seesaw, the loads ofthe belts 9 and 10 can be combined on one belt. The seesaw 12 or a beltthat is downstream of the seesaw can be operated at a different speedthan the seesaw itself or belts 9 and 10 in order to increase ordecrease the distance between two rows.

FIG. 30 shows yet another embodiment of the present invention. In thepresent case, sticks 21 are inserted into the patties after and/or whilethe patties are formed. The mold plates therefore comprise one slot 20per cavity, which guides the stick during its insertion into the patty.The stick can be inserted into the patty by moving the stick and/or bymoving the mold plate. The slots 20 are open towards the bottom andextend from the cavity towards the side limit 23 of the mold plate 2that is perpendicular to the motion of the mold plate which is depictedby the double arrow. Due to the opening of the slot 20 towards thebottom, the patty plus the stick can be easily deformed from the cavityof the mold plate. Due to the direction of the slot in the plate,patties are formed whose stick points in the direction of the motion ofthe belt (patties on belt 10) and whose stick is directed opposite ofthe motion of the belt (patties on transportation belt 9).

By means of for example a seesaw 12 as depicted in FIGS. 24-29, apattern as depicted in FIG. 31 can be created. The person skilled in theart understands that this pattern also requires that belt 9, belt 10,the sea saw and/or belt 24 downstream of belt 9 and 10 and/or the seesawhave to be movable sideward, i.e. horizontally and perpendicularly tothe direction of motion of the belt and/or a motion with such acomponent. The pattern according to FIG. 31 has the advantage, that thepatty load per unit area of a belt can be increased which isadvantageous for further processing of the patties and/or the packagingof the patties because a relatively smaller package is needed. Theperson skilled in the art understands, that this is also true forpatties without a stick.

Staggered patties as depicted in FIG. 31 can also be achieved byarranging the cavities in the mold plate 2 in a staggered mode, asdepicted in FIG. 32. With such a mold plate, the sideward motion of oneof the belts and/or the seesaw is not needed.

LIST OF REFERENCE SIGNS

-   1 form member, plate, drum, food forming apparatus-   2 de-aeration member, frame, mould plate-   3 food product forming apparatus, filling position-   4 housing, discharge position-   5 base member, cavities-   5.1 cavities being emptied-   5.2 cavities being filled-   6 guides, filling station-   7 closure member, porous mould region, second discharge station-   8 ventilation holes, ejection medium supply, first discharge station-   9 chamber, locking plate, first belt-   9′-9″′ segments of the first belt-   10 feed opening, rolling element, zylinder, second belt-   11 mould, insert, plate, bottom plate, means-   12 recess, plate, top plate, seesaw-   13 pressure member, inlet, outlet of the filling station-   14 opening, outlet, first outlet means-   15 groove, seal plate, second outlet means-   16 pressure element, spring element, inlet of the filling station-   17 groove, mould plate, divider-   18 pressure element, spring element, divider, axis-   19 knock out cup, ejection medium, air, axis-   20 permeable bottom, arrow, dropping patty, slot-   21 transportation means, transportation belt, patty-material supply,    stick-   22 patty, product in the cavity, row of cavity-   23 blade, side limit-   24 piston, belt-   25 channel, patty-   26 cavity, roller cage, gas, air-   27 indentation, belt, vent-   28 branch, patty transport-   29 stick-   30 opening, slot-   31 pressure transfer means, lamellas-   32 ejector-   33 food mass-   34 stick insertion unit-   35 insertion pin-   36 front end of the forming member-   W width of the mould plate-   L region, in which the cavities are arranged, porous mould region

1. A food product forming apparatus to produce patties with a formmember which comprises: a mould in which the patties are formed, whereinthe form member is located adjacent to a pressure member and is at leastpartially made from a porous material, wherein the patties are removedfrom the moulds by ejecting a gas, and wherein the form member is arotating drum and the pressure element is 3D-shaped and the surface ofthe form member, which interacts with the pressure member, 3D shaped, sothat a product is formed that does not comprise a constant thicknessover the product's entire extension. 2-46. (canceled)
 47. The foodproduct forming apparatus according to claim 1, wherein the food productforming apparatus comprises an adjustable spring element between a baseelement and the pressure member.
 48. The food product forming apparatusaccording to claim 1, wherein a blade is at least partially integratedin the pressure member.
 49. The food, product forming apparatusaccording to claim 48, wherein the pressure member comprises en openingand that the blade is located at a circumference of the opening.
 50. Thefood product forming apparatus according to claim 48, wherein the bladeis cut into the pressure member by water-jet-cutting.
 51. The foodproduct forming apparatus according to claim 48, wherein the blade isserrated and/or waved and/or straight.
 52. The food product formingapparatus according to claim 1, wherein a vacuum is applied to the formmember to avoid unintentional release of the patty.
 53. The food productforming apparatus according to claim 1, wherein water is applied to theform member after the patties e been released.
 54. The food productforming apparatus according to claim 1, wherein several raw of areproduced simultaneously.
 55. The food product forming apparatusaccording to claim 1, wherein inserts are connected to an ambient and/ora pressure-medium-system.
 56. The food product forming apparatusaccording to claim 1, comprising a stick insertion unit, wherein thestick insertion unit is movable, along at least circular arc.
 57. Thefood product forming apparatus according to claim 6, wherein the stickinsertion unit is located at a front end of a drum.
 58. The food productforming apparatus according to claim 56, the food product formingapparatus comprises a cam that pushes a stick into the patty, while theform member is advancing.
 59. The food product forming apparatusaccording to claim 56, wherein the food product forming apparatusincludes a means that is a slot
 60. The food forming apparatus accordingto claim 1, wherein the food product forming apparatus comprises adivider to divide the gas flow between two or more cavities.
 61. Thefood product forming apparatus according to claim 47, wherein a blade isat least partially integrated in the pressure member.
 62. The foodproduct forming apparatus according to claim 49, wherein the blade iscut into the pressure member by water-jet-cutting.
 63. The food productforming apparatus according to claim 62, wherein the blade is serratedand/or waved and/or straight.
 64. The food product forming apparatusaccording to claim 63, wherein inserts are connected to an ambientand/or a pressure-medium-system.
 65. The food product forming apparatusaccording to claim 64, comprising a stick insertion unit, wherein thestick insertion unit is movable, along at least a segment of a circulararc.